New Mattress Foam Factory in Libya: 16-Component Continuous Foaming Line Project

A client in Libya planned to build a new mattress foam factory to establish local mattress foam production capacity and support its own furniture and mattress-related business. The client had experience in foam trading and related industries, with a basic understanding of local demand and sales channels. Continuous foaming production, however, was still a new production stage for the team.

During project planning, the client set a target capacity of 200 blocks per day. The equipment solution also needed to support color variety, production cost control and technical support during the start-up stage. After remote communication and an on-site visit to Sabtech’s factory in China, Sabtech recommended a 16-component continuous foaming line based on the client’s product direction, capacity plan and production start-up conditions.

Project Background

The client’s project goal was clear: to build a continuous foaming line for conventional mattress foam production, create stable local production capacity and reduce dependence on externally purchased foam.

This was a new PU foam factory project. The client already had experience in foam trading and furniture / mattress-related business, which helped them understand local market demand. Continuous foaming production involves equipment operation, formulation adjustment, production control and on-site management, so the client needed more specific support during the production start-up stage.

The basic project conditions included:

Project location: Libya

Project type: New mattress foam factory

Planned product: Conventional mattress foam

Target capacity: 200 blocks per day

Client background: Foam trading and furniture / mattress-related business experience

Equipment scope: 16-component continuous foaming line

Main Concerns Before Order Confirmation

Before confirming the equipment solution, the client mainly focused on four concerns:

Lack of continuous foaming experience and concern about production start-up difficulty;

Whether formulation adjustment and production technology could receive continuous support;

Whether the equipment could provide a stable basis for daily production;

Whether the project investment could match future production and payback expectations.

These concerns directly affected the client’s supplier selection. The client cared about the equipment configuration, and also paid close attention to the supplier’s foaming process experience and ability to provide technical support after installation, commissioning and production start-up.

Before the solution was confirmed, Sabtech explained the equipment structure, continuous foaming line operation and project support approach through remote communication and video demonstrations. The client later visited Sabtech’s factory in China to review equipment manufacturing, continuous foaming line structure, running demonstrations, after-sales support and technical service capability.

The client finally chose Sabtech mainly because of Sabtech’s long-term technical support and foaming process experience. For a new factory without a mature continuous foaming team, these two factors were closely related to installation, commissioning and production start-up.

Why a 16-Component Continuous Foaming Line Was Selected

The 16-component continuous foaming line was not specified by the client at the beginning. It was recommended by Sabtech during project communication based on the client’s actual project conditions.

The selection was mainly based on four considerations:

The planned mattress foam factory needed to meet daily output requirements;

The client wanted more flexibility for future color production and different mattress foam color requirements;

The powder tank configuration could support the client’s formulation structure and help control production costs;

The client may expand capacity or add new product types in the future, so the initial configuration needed to leave room for later adjustment.

This configuration matched both the client’s current production plan and future development needs. It covered conventional mattress foam production, supported multiple color requirements, and gave the new factory clearer operating and control conditions during the start-up stage.

16-Component Configuration Structure

The 16-component continuous foaming line configured by Sabtech mainly included:

 PPG

Powder tank

POP

TDI

MC

Silicone oil

A33

T-9

Water

Black color system

Five additional color tanks

Spare tank

Key Control Configuration

The production line was equipped with a PLC control system and mass flow meters. The mass flow meters support material metering and automatic compensation, helping each component maintain high-precision ratio control.

For a new factory, a clear metering and control system helps reduce dependence on operator experience during the start-up stage and makes the continuous foaming process easier for the client team to manage.

The production line was also equipped with foam height monitoring for observing and managing the foaming status on site.

Project Execution Process

The project communication started in October 2023. The solution was confirmed in December 2023, and the order was confirmed in January 2024.

• October 2023: First communication

• December 2023: Solution confirmation

• January 2024: Order confirmation

• January 2024: Equipment production

• May 2024: Shipment

• July 2024: Equipment arrival

• August 2024: On-site installation

• September 2024: Commissioning

• September 2024: Production start-up

After the equipment arrived at the client’s factory, Sabtech engineers went to the site for installation and commissioning. During the installation and commissioning stage, the client team received training on equipment operation, daily maintenance, basic troubleshooting, production process coordination, safety precautions and formulation adjustment.

Operation Status After Start-Up

The project completed commissioning and entered production in September 2024. The production line is currently running normally and continues to be used for conventional mattress foam production.

The client team has completed basic operation and daily maintenance training and can carry out regular production management. After production start-up, Sabtech continues to provide technical support to help the client handle technical issues during subsequent production.

Reference Value for Similar Projects

This case is suitable for:

Investors planning a new PU foam factory;

Clients preparing to enter mattress foam production;

Companies extending from foam trading, furniture or mattress-related business into foam manufacturing;

Clients without a mature foaming team who need supplier support during production start-up.

Before confirming a continuous foaming line configuration, similar projects should first clarify product direction, daily output, color requirements, cost control targets, operator experience and future expansion plans. For clients entering mattress foam production for the first time, the supplier’s foaming process experience, on-site installation and commissioning capability, and long-term technical support should be included in the configuration decision.

If your project is also in the planning stage for a new mattress foam factory, you can first discuss the target product, planned daily output, color requirements and production start-up support conditions before deciding the component configuration and automation level of the continuous foaming line.